JCB 135 HD, 155 HD Skid Steer Loader Service Repair Manual Instant Download (SN 2431601 and up)

1
Foreword
SERVICE MANUAL SKIDSTEER LOADER 135 HD, 155
HD EN - 9813/4450 ISSUE 2 -
03/2017 This manual contains original
instructions, verified by the manufacturer (or
their authorized representative). Copyright
7-03-08 JCB SERVICE All rights reserved. No
part of this publication may be reproduced,
stored in a retrieval system, or transmitted in
any form or by any other means, electronic,
mechanical, photocopying or otherwise, without
prior permission from JCB SERVICE. www.jcb.com
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine
you do not understand.
Treat the Operator's Manual as part of the
machine. Keep it clean and in good condition.
Replace the Operator's Manual immediately if it
is lost, damaged or becomes unreadable.
Contents 01 - Machine
03 - Attachments, Couplings and Load Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating Conditioning (HVAC) 15
- Engine
and Air-
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
2
18 - Fuel and Exhaust System 18 - Injection 21 -
Governor
Component Identification
Operation
Figure 268. Governor control mecha- nism in the
front housing without a BCD
The fuel rack is connected to the linkage, which
controls the fuel injection pump. This linkage is
located in the front case.
A
The engine has a mechanical governor to control
the engine speed. The governor operates for all
engine RPM (Revolutions Per Minute). The
governor weight assembly is installed on the
front of the camshaft gear. The other components
of the governor are installed in the front case.
B
Figure 270. Governor control mecha- nism in the
front housing without a BCD
F
C
A
E
D
B

• Connection for the linkage to the fuel injection
  pump
• Control lever
• Lever return spring
• Governor adjustment screw
• Arm
• Start spring
• Figure 269. Governor control mecha- nism in the
  front housing with a BCD

F
C
E
D
A

1. Connection for the linkage to the fuel injection
   pump
2. Control lever
3. Lever return spring
4. Governor adjustment screw
5. Arm
6. Start spring

B
G
J

• H
• Connection for the linkage to the fuel injection
  pump
• Control lever
• G Governor main spring H Adjuster (Angleich
  unit) J Governor lever

18 - 34
3
18 - Fuel and Exhaust System 18 - Injection 21 -
Governor
Figure 271. Governor control mecha- nism in the
front housing with a BCD
A spring connects the linkage to the fuel
injection pump and the mechanical stop control.
When the engine is first started, the spring
automatically increases the fuel flow to the
cylinders.
A
B
G
J

• H
• Connection for the linkage to the fuel injection
  pump
• Control lever
• G Governor main spring H Adjuster (Angleich
  unit) J Governor lever
• The movement of the governor weight assembly is
  transferred to the fuel rack on the fuel
  injection pump by the control lever, the
  governor lever and the linkage to the fuel
  injection pump. The governor main spring
  connects the governor lever to the control
  lever. The governor main spring controls the
  movement of the governor weight assembly on the
  camshaft. When the angle of the control lever
  changes, the tension on the governor main spring
  changes. This action controls the linkage to the
  fuel rack on the fuel injection pump, which
  controls the engine RPM.
• The maximum fuel adjustment screw is mounted in
  the front case. This adjustment regulates the
  fuel injection at high engine RPM. This
  adjustment should only be made by personnel with
  the correct training.
• The fuel injection pump timing, the low idle and
  the high idle are preset at the factory.
  Adjustments to the pump timing and idle RPM
  should only be made by personnel that have had
  the correct training. The timing for the fuel
  injection pump should only change if the
  camshaft or the crankcase are replaced. The fuel
  injection pump timing should not change if the
  fuel injection pump is reinstalled with a shim
  that is the same size.
• The fuel rack automatically returns to the excess
  fuel position when the engine is stopped. The
  excess fuel position helps the engine to
  starting in cold conditions.

18 - 34
4
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com
5
18 - Fuel and Exhaust System 18 - Injection 21 -
Governor
Adjust Special Tools
Figure 273.
Description Part No. Qty.
Digital Tachometer 892/00284 1
D E
The setting of the front case is only necessary
if the front case is damaged or if the front
case is renewed.
F
Record the Governor Settings

• If the front case is removed, install the front
  case. Refer to (PIL 15-51).
• Record the setting of the low idle stop screw and
  the high idle stop screw. This is to make sure
  the governor operation is restored.
• Operate the engine until the normal operating
  temperature is reached.
• Record the engine RPM (Revolutions Per Minute)
  at low idle with an optical tachometer.
• Special Tool Digital Tachometer (Qty. 1)
• Accelerate the engine to high idle. Record the
  engine RPM as Speed A with an optical
  tachometer.
• Figure 272.

G

• Idle trimmer screw
• Locknut
• High idle stop screw
• Low idle stop screw
• Remove the tamperproof caps.
• Record the protrusion of the high idle stop
  screw.
• Record the protrusion of the low idle stop screw.
• Release the locknut. Turn the high idle trimmer
  screw four turns counterclockwise and tighten
  the locknut.

A

1. Accelerate the engine to high idle. Record the
   engine RPM as Speed B with an optical
   tachometer.
2. Make sure that the recorded Speed B is lower
   than the recorded Speed A.

B
C
Removal of the Old Front Case

1. Remove the fuel injection pump. Refer to (PIL
   18-18).
2. Remove the crankshaft pulley. Refer to (PIL
   15-12).
3. Remove the front case. Refer to (PIL 15-51).

1. Tamperproof caps
2. Protrusion of the high idle stop screw
3. Protrusion of the low idle stop screw

6
18 - Fuel and Exhaust System 18 - Injection 21 -
Governor
Figure 274.
Figure 276.
V
K
U
L

• Calibration spring
• Start spring
• Install the front case. Refer to (PIL 15-51).
• Do not install a gasket. Refer to Figure 274.
• Install the fuel injection pump. Refer to (PIL
  18-18).
• Install the original shim.
• Install the crankcase adaptor into the crankcase.

• U Front case
• V Gasket
• Remove the gasket. Make sure that the face of
  the front plate is clean.
• Install the Allen head screw to the lever
  assembly. Tighten the Allen head screw to the
  correct torque value.
• Figure 275.

• Install the DTI (Dial Test Indicator) holder into
  the crankcase adaptor.
• The DTI must be graduated to the specified
  dimension.
• Dimension 0.01mm
• Assemble the DTI and the extension to the
  specified dimension.
• Dimension 20mm
• Figure 277.

H
J
H Allen head screw (M4 x 20mm x 0.70) J Lever
assembly
P
6. Remove the start spring and replace the start
spring with a calibration spring.
N
Q

• M
• DTI
• DTI holder
• Crankcase adaptor
• Crankcase

7
18 - Fuel and Exhaust System 18 - Injection 21 -
Governor

• Install the DTI into the DTI holder until the
  extension on the DTI touches the rack of the fuel
  injection pump.
• Push the assembled DTI and the extension into
  the DTI holder further to the specified distance.
• Dimension 2mm
• Figure 278.

1. Remove the crankcase adaptor. Refer to Figure
   277.
2. Remove the fuel injection pump. Refer to (PIL
   18-18).
3. Remove the front case. Refer to (PIL 15-51).
4. Remove the calibration spring and install the
   original start spring. Refer to Figure 276.
5. Remove the Allen head screw from the lever
   assembly. Refer to Figure 275.
6. Install the new gasket on the front case. Make
   sure that the gasket is clean and free from
   damage. Refer to Figure 274.
7. Install the new front case. Refer to (PIL 15-51).
8. Set the protrusion of the high idle stop screw to
   the same dimensions as the stop screws on the
   original front case. Refer to Figure 272.

N
P
M
R
10. Set the protrusion of the low idle stop screw
to the same dimensions as the stop screws on the
original front case. Refer to Figure 272.

• Set the high idle trimmer screw as follows Refer
  to Figure 273.
• Release the locknut.
• Set the high idle trimmer screw to the fully out
  position.
• Turn the screw clockwise for two turns.
• Tighten the locknut.
• Install the fuel injection pump. Refer to (PIL
  18-18).
• Start the engine and allow the engine to reach
  the normal operating temperature.
• Run the engine at low idle and adjust the low
  idle stop screw to the speed that was previously
  recorded, prior to the original front case
  removal.
• Run the engine at high idle and adjust the high
  idle stop screw to the speed that was previously
  recorded as Speed B.
• Run the engine at high idle and release the
  locknut.
• Adjust the high idle trimmer screw to the speed
  that was previously recorded as Speed A.
• Tighten the locknut.
• Make sure that the recorded Speed B is lower
  than the recorded Speed A.
• Make sure that the engine operates correctly.

• DTI
• DTI holder
• P Crankcase adaptor
• R Crankcase
• Lock the DTI holder to retain the DTI in
  position. Set the DTI to the specified
  dimension.
• Dimension 2 0.01mm
• Push the plunger of the DTI several times to seat
  the rack of the fuel injection pump. When the
  plunger is gently released, check that the DTI
  reads the specified dimension.
• Dimension 2 0.01mm
• If the rack of the fuel injection pump has heavy
  resistance to movement
• Remove the DTI.
• Remove the fuel injection pump.

1. Wash the fuel injection pump suitable cleaner.
2. Install the fuel injection pump.
3. Repeat the steps 12 to 15.

with a
17. Do the calibration of the fuel screw and the
front housing. Refer to (PIL 18-18).
Final Installation of the New Front Case 1.
Remove the DTI and the DTI holder. Refer to
Figure 277.
8
18 - Fuel and Exhaust System 18 - Injection 21 -
Governor
Calibrate

• Install the tamperproof cap to the high idle
  trimmer screw and the high idle screw.
• Carefully install the tamperproof cap to the fuel
  screw.
• Figure 279.

Setting the Fuel Screw
1. Release the plunger of the Indicator). Refer
to Figure 280. Figure 280.
DTI (Dial Test
N
P
W
M
R
W Fuel screw
Table 98. Torque Values

• DTI
• DTI holder
• P Crankcase adaptor
• R Crankcase
• Do not move the position of the DTI, DTI holder
  and crankcase adaptor.
• Retain the locknut of the fuel screw in position
  with a ring spanner. Refer to Figure 281.
• Figure 281.

Item Description Nm
H Allen head screw .4
S
T

• Allen wrench
• Ring Spanner
• 4. Turn the Allen head screw and observe the
  reading on the DTI.

9
18 - Fuel and Exhaust System 18 - Injection 21 -
Governor

• Turn the Allen head screw until the DTI reads the
  specified dimension.
• Dimension 2 0.01mm
• Tighten the locknut to the correct specified
  torque value.
• Torque 6Nm
• Make sure that the reading on the DTI is as
  specified.
• Dimension 2 0.01mm
• Install and adjust the new front case. Refer to
  (PIL 15-51).

10
18 - Fuel and Exhaust System 18 - Injection 24 -
Adjuster
Remove and Install Consumables
Description Part No. Size
JCB Threadlocker and Sealer (Medium Strength) 4101/0250 0.01L
JCB Threadlocker and Sealer (Medium Strength) 4101/0251 0.05L

• Remove
• Disassemble the timing gear front case. Refer to
  (PIL 15-51).
• Remove the lever assembly from the front case.
• Remove the adjuster unit from the lever
  assembly. Refer to Figure 282.
• Figure 282.

G
K

• G Lever assembly
• K Adjuster unit
• Install
• Apply threadlocker on the first two threads of
  the adjuster unit.
• Consumable JCB Threadlocker and Sealer (Medium
  Strength)
• Install the adjuster unit to the lever assembly.
• Tighten the adjuster unit to the correct torque
  value.
• Make sure that the threadlocker does not
  contaminate the plunger assembly of the adjuster
  unit. The contamination of the plunger assembly
  will make the adjuster unit inoperative.
• Install the lever assembly to the front case.
• Assemble the timing gear front case. Refer to
  (PIL 15-51).

18 - 42
18 - 42
11
18 - Fuel and Exhaust System 21 - Fuel Pump 00 -
General
Remove and Install

• Disconnect the electrical connector from the fuel
  pump.
• Plug all the open ports and hoses to prevent
  contamination.
• The fuel transfer pump can be oriented in two
  positions. Before you remove the fuel pump from
  the crankcase, note the orientation of flange on
  the fuel pump for installation.
• Loosen the clamps and disconnect the hoses.
• Put a label on the hoses to help installation.
• Loosen the bolt and remove the fuel pump from
  the crankcase.
• If necessary, rotate the crankshaft until the
  operating plunger of the fuel pump is not under
  pressure to remove the fuel pump.

Observe all the health and safety information.
Refer to Fuel system - Health and Safety (PIL
18-00).
Electrical Fuel Pump Remove

• Make the machine safe. Refer to (PIL 01-03).
• Open the rear access cover. Refer to (PIL 06-06).
• Turn the fuel supply to the OFF position.
• Disconnect the electrical connector from the fuel
  pump.
• Plug all the open ports and hoses to prevent
  contamination.
• Loosen the clamps and disconnect the hoses.
• Put a label on the hoses to help installation.
• Remove the bolt1 (x2) and remove the fuel pump.
• Figure 284.

10. Remove the O-ring seal from the fuel
pump. Figure 285.
F
G
B
A
H
C
D
D
E
E
J

1. Electrical connectors
2. Bolt1 (x2)
3. Fuel pump (Electrical)
4. Clamps
5. Hoses

K
Install

• Fuel pump (Mechanical)
• Bolt2
• O-ring seal
• Bolt3
• Flange

1. The installation procedure is the opposite of the
   removal procedure. Additionally do the following
   steps.
2. Make sure that the electric transfer pump is
   clean and free from damage.
3. Bleed the fuel system. Refer to Fuel system (PIL
   18-00).

Install

1. Clean the mating surfaces of the crankcase and
   the flange on the fuel pump.
2. Make sure that the camshaft lobe for the fuel
   pump is at the minimum lift before the fuel pump
   is installed.
3. Make sure that the fuel pump is oriented in the
   correct position.
4. Install the new O-ring seal to the fuel pump.

Mechanical pump Remove

1. Make the machine safe. Refer to (PIL 01-03).
2. Open the rear access cover. Refer to (PIL 06-06).
3. Turn the fuel supply to the OFF position.

18 - 47
12
18 - Fuel and Exhaust System 21 - Fuel Pump 00 -
General

• Lubricate the operating plunger of the fuel pump
  with clean engine oil.
• Position the fuel pump on the crankcase.
• Make sure that the operating plunger is
  positioned correctly on the camshaft lobe.
• Install the bolt3.
• Tighten the bolt3 to the correct torque value.
• Connect the hoses to the fuel pump.
• Tighten the hose clamps.
• The inlet for the fuel pump can be rotated to the
  specified angle by loosening bolt2.
• Angle 360
• The fuel inlet is adjustable to the specified
  degree increments.
• Angle 15
• If adjustment is made to the position of the
  fuel inlet, tighten bolt2 to the correct torque
  value.
• Turn the fuel supply to the ON position.
• Bleed the fuel system. Refer to Fuel system (PIL
  18-00).
• Table 99. Torque Values

Item Description Nm
B Bolt1 9
G Bolt2 2.5
J Bolt3 6
18 - 47
13
18 - Fuel and Exhaust System 35 - Turbocharger 00
- General
00 - General
Introduction
Introduction .....................................
............... 18-63 Component Identification
............................... 18-64 Operation
..................................................
..... 18-65 Check (Condition) ....................
...................... 18-65 Check (Operation)
.........................................
18-66 Remove and Install .........................
.............. 18-67 Store and Recommission
.............................. 18-69
A turbocharger increases the temperature and the
density of the air sent to the engine cylinder.
This condition causes a lower temperature of
ignition to develop earlier in the compression
stroke. The compression stroke is also timed in
a more accurate way with the fuel injection. The
surplus air lowers the temperature of
combustion. This surplus air also provides
internal cooling.

• A turbocharger improves the following aspects of
  engine performance
• Power output is increased.
• Engine torque is increased.
• Engine efficiency is increased.
• Figure 289.
• G

B D
F
A
H
C
J
E

• K
• L
• Air intake
• Compressor housing C Compressor wheel D
  Bearing
• Oil inlet port
• Bearing
• Turbine housing
• Turbine wheel J Exhaust outlet K Oil outlet
  port L Exhaust inlet

18 - 63
14
18 - Fuel and Exhaust System 35 - Turbocharger 00
- General
Component Identification
Figure 290.
A
G H
E
T
W
V
E
B
B
D
F
J
Q N
U
C
K
S
M L
R
P
A Air inlet hose C Screw E Turbocharger G Banjo
bolt J Tube clips L Tube assembly 1 N Bolt 2 Q
Joint 1 S Bolt 3 U Gasket 2 W Tube connector
B Hose clamp D Exhaust elbow F Gasket 1 H Washer
K Bolt1 M O-ring P Tube assembly 2 R Joint 2 T
Nut V Stud
18 - 63
15
18 - Fuel and Exhaust System 35 - Turbocharger 00
- General
Operation
Check (Condition)

1. Inspect the compressor and turbine for damage.
2. Make sure that the compressor blades do not rub
   on the housing and rotate freely. It is normal to
   detect a bit of play on the blades.
3. Make sure that the shaft rotates freely.
4. Before you install the turbocharger, make sure
   that the code of the component is correct for
   the type of engine, as installation of the wrong
   turbocharger can damage the turbo and engine and
   void the warranty.

The turbocharger is installed between the exhaust
manifold and the intake manifold. The
turbocharger is driven by exhaust gases which
flow through the exhaust inlet. The energy of
the exhaust gas turns the turbine wheel. Then,
the exhaust gas flows out of the turbine housing
through the exhaust outlet.
The turbine wheel and the compressor wheel are
installed on the same shaft. Therefore, the
turbine wheel and the compressor wheel rotate at
the same RPM (Revolutions Per Minute). The
compressor wheel is enclosed by the compressor
housing. The compressor wheel compresses the
intake air. The intake air flows into the engine
cylinders through the inlet valves of the
cylinders.
The oil from the main gallery of the crankcase
flows through the oil inlet port to lubricate the
turbocharger bearings (Bearing1 and bearing2).
The pressurised oil passes through the bearing
housing of the turbocharger. The oil is returned
through the oil outlet port to the oil pan. The
turbocharger has a wastegate. The wastegate is
controlled by the boost pressure. This allows
some of the exhaust gases to bypass the turbine
wheel at higher engine speeds. The wastegate is
a type of flapper valve that automatically opens
at a preset level of boost pressure in order to
allow the exhaust gas to flow around the
turbine. The wastegate allows the design of the
turbocharger to be more effective at lower
engine speeds.
18 - 63
16
18 - Fuel and Exhaust System 35 - Turbocharger 00
- General
Check (Operation) To maximise the duration of
the turbocharger follow the rules described
below. Start-up Start the engine and keep it at
idle speed for about a minute. The oil operating
pressure is reached within a few seconds, but it
is useful to allow the moving parts to warm up
in good lubrication conditions. Immediately
increasing the engine speed after start up will
result in the turbocharger running at high rpm
with less than optimal lubrication. This may lead
to premature failure of the turbocharger. After
maintenance When carrying out maintenance on the
engine or turbocharger, pre-lubricate the oil
inlet of the turbocharger by adding clean
lubricant until it is completely full. After
pre-lubrication, let the engine run via the
starter motor without firing (engine / fuel pump
stop out) to allow the oil to circulate through
the complete system under pressure. Upon engine
start-up, make it run at idle speed for a few
minutes, allowing the oil and bearings system to
work satisfactorily. Low temperature air or
engine inactivity If the engine has been inactive
for a certain period of time or the air
temperature is very low, start the engine and
then let it run at idle speed. This enables the
oil to go into the lubrication system before
applying high loads and speeds to the engine and
turbocharger. Engine shutdown Before switching
the engine off after intense activity, you must
allow the turbocharger to cool down, let the
engine run at idle speed for at least 2 minutes
to allow the turbocharger to cool. Engine at
idle speed Avoid running the engine at idle speed
for long periods (above 20-30 minutes). Idle
operation leads to low pressure values in the
turbocharger, which may cause oil leaks from the
seals at the ends of the turbo bearing shaft.
Even if this does not cause damage, it can cause
blue smoke from the exhaust when the engine
speed and load are increased.
18 - 63
17
18 - Fuel and Exhaust System 35 - Turbocharger 00
- General
Remove and Install
Remove

1. Remove the bolt 1 and remove the tube assembly 1
   from the crankcase.
2. Remove and discard the O-ring.
3. Remove the bolt 2 and disconnect the tube
   assembly 2 from the turbocharger.
4. Remove and discard the joint 1.
5. If necessary, remove the bolt 3 and remove the
   tube assembly 2 from the crankcase.
6. Remove and discard the joint 2.
7. Remove the nut and the turbocharger from the
   exhaust manifold.
8. Remove and discard the gasket 2 from the exhaust
   manifold.
9. If necessary, remove the stud from the exhaust
   manifold.

1. Make sure you obey the special instructions on
   handling, operation and installation of the
   turbocharger. Refer to (PIL 18-35).
2. Make the machine safe. Refer to (PIL 01-03).
3. Make sure that the engine is safe to work on. If
   the engine has been running, let it cool before
   you start the service work.
4. Loosen the hose clamp and remove the air inlet
   hose.
5. Remove the screw and remove the exhaust elbow.
6. Remove the gasket 1.
7. Remove the banjo bolt and the washer.
8. Remove the fasteners and spacers from the tube
   clips.

Important Do not use the actuator rod of the
wastegate to lift the turbocharger.
Figure 291.
A
G H
E
T
W
V
E
B
B
D
F
J
Q N
U
C
K
S
M L
R
P
A Air inlet hose C Screw E Turbocharger G Banjo
bolt J Tube clips L Tube assembly 1 N Bolt2 Q
Joint 1 S Bolt 3 U Gasket 2 W Tube connector
B Hose clamp D Exhaust elbow F Gasket 1 H Washer
K Bolt1 M O-ring P Tube assembly 2 R Joint 2 T
Nut V Stud
18 - 63
18
18 - Fuel and Exhaust System 35 - Turbocharger 00
- General
Install

• Keep the tube assembly 1 at its correct position
  on the turbocharger.
• Install the tube clips with the fasteners and
  spacers.
• Tighten the banjo bolt to the correct torque
  value.
• Make sure that the tube assemblies do not touch
  any other components.
• Clean the mating surfaces of the exhaust elbow.
• Keep the new gasket 1 and exhaust elbow at its
  correct position on the turbocharger.
• Install the screw and tighten to the correct
  torque value.
• Make sure that the inlet hoses are clean and free
  from the defects or restrictions.
• Loosely install the hose clamps on the air inlet
  hose.
• Install the inlet hose and then tighten the hose
  clamps.
• Table 101. Torque Values

1. Make sure that all the parts are clean and free
   from contamination.
2. Check the turbocharger for wear or damage. If
   the turbocharger is worn, replace the complete
   turbocharger.
3. Check the actuator for correct operation. Refer
   to (PIL 18-35).
4. If the actuator is damaged or does not operate
   within the specified limits, replace the complete
   turbocharger.
5. Clean the mating surfaces of the exhaust
   manifold.
6. If removed, install the studs to the exhaust
   manifold.
7. Tighten the studs to the correct torque value.
8. Install the new gasket 2 on the studs.
9. Keep the turbocharger on the exhaust manifold at
   its correct position.

1. Install the nuts and tighten to the correct
   torque value.
2. Make sure that the tube assembly 1 and tube
   assembly 2 are clean and free from damage. If
   necessary, replace the tube assemblies.
3. If removed, keep the new joint 2 at its correct
   position on the crankcase with the tube assembly
   2.
4. Install the bolt 3 and tighten to the correct
   torque value.
5. Keep the new joint 1 at its correct position on
   the tube assembly 2. Align the tube assembly 2
   with the bottom of the turbocharger.
6. Install the bolt 2 and tighten to the correct
   torque value.
7. Lubricate the bearings of the turbocharger with
   the clean engine oil through the oil inlet port.
8. Rotate the shaft of the turbocharger to
   distribute the oil.
9. Install the new O-ring on the tube assembly 1.
10. Keep the tube assembly 1 at its correct position
    on the crankcase.
11. Install the bolt 1 and tighten to the correct
    torque value.
12. Install the new washer and banjo bolt to the tube
    assembly 1.

Item Description Nm
C Screw 32
G Banjo bolt 18
K Bolt 1 10
N Bolt 2 10
S Bolt 3 10
T Nut 25
V Stud 18
18 - 63
19
18 - Fuel and Exhaust System 35 - Turbocharger 00
- General
Store and Recommission

• allowing the oil and bearings system to work
  satisfactorily.
• Low temperature air or engine inactivity If the
  engine has been inactive for a certain period of
  time or the air temperature is very low, start
  the engine and then let it run at idle speed.
  This enables the oil to go into the lubrication
  system before applying high loads and speeds to
  the engine and turbocharger.
• Engine shutdown Before switching off the engine
  after intense use allow the turbocharger to cool
  down. Therefore run the engine at idle speed for
  at least 2 minutes that allow the turbocharger
  to cool down.
• Engine at idle speed Do not run the engine at
  idle speed for more than 20-30 minutes at a time.
  It may cause oil leaks from the seals at the end
  of the engine shaft or it can cause blue smoke
  from the exhaust when the engine speed and load
  are increasing.

What to do

• Before assembling the turbocharger, make sure
  that the protection caps are installed on all
  openings of the turbocharger.
• Make sure that the packaging is correct before
  storing the turbocharger to be assembled.
• Make sure the turbocharger is pre-lubricated.
• Periodically check that the joints are sealed
  against oil and air.
• Use only the specified lubricating oil.
• Check the engine oil level.
• Before switching the engine off after use, let it
  run at idle speed for around 1 minute.
• Check the condition of the air and oil filter
  regularly as per the maintenance schedules.
• Make sure that the engine maintenance intervals
  are observed.
• Make sure that the engine and equipment are used
  in a way that is not harmful to the life of the
  turbocharger.

• What not to do
• Do not store the turbochargers in stacks.
• Do not store the turbochargers in damp or wet
  conditions.
• Do not expose the turbochargers to dust and
  dirt.
• Do not lift the turbocharger by holding the
  actuator rod.
• Do not increase the engine speed immediately
  after start-up.
• Do not run the engine at idle speed for more
  than 20-30 minutes at a time.
• Do not change the actuator settings.
• Practical operating rules
• Start-up Start the engine and keep it at idle
  speed for about a minute. The oil operating
  pressure is reached within a few seconds, but it
  is useful to allow the moving parts to warm up
  in good lubrication conditions. Immediately
  increasing the engine speed after start up will
  result in the turbocharger running at high RPM
  (Revolutions Per Minute) with less than optimal
  lubrication. This may lead to premature failure
  of the turbocharger.
• After maintenance When carrying out maintenance
  on the engine or on the turbocharger,
  pre-lubricate the oil inlet of the turbocharger
  by adding clean lubricant until it is completely
  full. After pre-lubrication, let the engine run
  via the starter motor without firing, to allow
  the oil to circulate through the complete system
  under pressure. Upon engine start-up,

make it run at idle speed for a few minutes,
18 - 69
20
Suggest If the above button click is invalid.
Please download this document first, and then
click the above link to download the complete
manual. Thank you so much for reading
21
18 - Fuel and Exhaust System 35 - Turbocharger 06
- Wastegate Valve
Check (Condition) WARNING Hot oil and engine
components can burn you. Make sure the engine is
cool before doing this job. Used engine
crankcase lubricants contain harmful
contaminants. In laboratory tests it was shown
that used engine oils can cause skin cancer.
Operation
The wastegate controls the amount of exhaust gas
that is allowed to bypass the turbine side of the
turbocharger. This valve then controls the RPM
(Revolutions Per Minute) of the turbocharger.
When the engine operates in conditions of low
boost, a spring presses against a diaphragm in
the canister. The actuating rod will move and
the wastegate will close. Then, the turbocharger
can operate at maximum performance.
Important The turbocharger is a non-serviceable
item. The pressure for the wastegate can be
checked but not adjusted. For a pressure check
of the wastegate, refer to (PIL 18-35).
When the boost pressure increases against the
diaphragm in the canister, the wastegate will
open. The RPM of the turbocharger becomes
limited. The RPM is limited because a portion of
the exhaust gases bypass the turbine wheel of
the turbocharger.
Before you check the condition of the wastegate,
make sure that the inlet air and exhaust system
restrictions are within the specified limits.

1. The following levels of boost pressure indicate a
   problem with the wastegate
2. Too high in full load conditions.
3. Too low in all low boost conditions.
4. The boost pressure controls the maximum RPM
   (Revolutions Per Minute) of the turbocharger,
   because the boost pressure controls the position
   of the wastegate. The following factors also
   affect the maximum RPM of the turbocharger
5. The engine rating.
6. The horsepower demand on the engine.
7. The high idle RPM
8. Inlet air restriction.
9. Exhaust system restriction.

18 - 71
22
18 - Fuel and Exhaust System 35 - Turbocharger 06
- Wastegate Valve

• Check (Pressure)
• Make sure you obey the special instructions on
  handling, operation and installation of the
  turbocharger. Refer to (PIL 18-35).
• Make the machine safe. Refer to (PIL 01-03).
• Make sure that the engine is safe to work on. If
  the engine has been running, let it cool before
  you start the service work.
• Get access to the turbocharger. Refer to (PIL
  06-06).
• Remove the heatshield from the turbocharger.
• Remove the guard for the wastegate.
• Remove the boost line from the wastegate.
• Connect an air supply to the wastegate that can
  be adjusted accurately.
• Install a DTI (Dial Test Indicator) to the
  turbocharger so that the end of the actuator rod
  is in contact with the plunger of the DTI. This
  will measure the axial movement of the actuator
  rod.
• Slowly apply air pressure to the wastegate so
  that the actuator rod moves to the specified
  distance.
• Distance 1mm
• Make sure that the air pressure applied is
  within the specified limit.
• Pressure 0.52bar (7.5psi)
• Make sure that the DTI returns to zero when the
  air pressure is released.
• Repeat the test several times to make sure that
  you get an accurate reading.
• If the wastegate does not operate correctly,
  contact your JCB dealer.

18 - 71
23
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com